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INVENTOR. I 7 72 017 flezmfgJz MOLDED ARTICLE Henry Beneke, Jr.,Columbus, Miss., assignor to Beneke Corporation, Columbus, Miss, acorporation of Mississippi Original application Dec. 8, 1953, Ser. No.396,891,

now Patent No. 2,709,280, dated May 31, 1955. Divided and thisapplication Apr. 21, 1955, Ser. No. 502,889

Claims. (Cl. 4-234) The present invention relates to molded articlesand, more particularly, to a novel molded article, such, for example, asa toilet seat or cover. This invention is a division of my copendingapplication, Serial No. 396,891, which was filed December 8, 1953, whichissued as Patent No. 2,709,280, dated May 31, 1955.

The present invention provides, in a novel way, an article having aunitary portion differing in physical characteristics from the remainderof the article. An article, such as a toilet seat, requires thathardware be secured to it. Reinforcement is needed in the toilet seat tohold fastening screws. Modern seats of better quality are molded, and inthe prior art, inserts have been provided to receive screws. These priorart inserts, although they are embedded, are not, in effect, integralwith the structure. In accordance with the present invention, anintegral portion of the structure is provided in a novel manner whichserves as a reinforcing insert.

An object of the invention is to provide a molded article having aninternal integral portion of a difierent character from the remainder ofthe article.

Another object of the invention is to provide a molded article having aportion of a different composition from the remainder.

A further object of the invention is to provide an article having aninternal portion surrounded by a material compatible with the materialof the article.

Still another object of the invention is to provide a cellulosecontainer having a moldable material sealed therein for inclusion in amolded structure.

Other and perhaps more specific objects will become apparent as thefollowing description proceeds in connection with the accompanyingdrawing in which:

Fig. l is a view in perspective of a toilet seat and cover to which theinvention may be applied;

Fig. 2 is a view of the underside of the cover with the cover lifted;

Fig. 3 is a view of the underside of the seat with the seat also lifted;

Fig. 4 is a section of the lid on line 4-4 of Fig. 2;

Fig. 5 is a section of the seat on line 55 of Fig. 3;

Fig. 6 is a perspective view of contained material in preparation forproduction of an insert; and

Fig. 7 is a fragmentary view in section of a mold to illustrate moldingof an article following procedures taught in the present invention.

Fig. 1 of the drawing shows a toilet seat 10 and a cover 12 of a typewhich may be molded to embody the invention. Hardware comprising seathinge connections 14 and lid hinge connections 16 are provided. Thehardware includes a fitting 18 for connection to a toilet bowl (notshown). The seat hinge connections or irons 1-4 are secured to the seat10 by means of screws 21 which are turned into the seat structure. Thecover hinge connections 16 are secured to the cover 12 by means ofscrews 22. These screw connections require extra strength in the body ofthe material to prevent loosening States Patent 0 of the screws andconsequent enlargement of the screw holes. Inserts have been used, butthese are diflicult to mold in and add to the cost. Moreover, thepresence of an insert tends to weaken the structure since crosssectional areas of the molded structure are reduced at points of appliedstress. By practicing the present invention, all of the benefits ofinserts are realized without any of the disadvantages. The total crosssection of the molded structure is available to resist stress and itsmechanical resistance is enhanced. There is no possibility of an in sertworking loose.

Referring to Fig. 5 of the drawing, the seat 10 is shown in crosssection. Fig. 4 is a similar view for the cover 12. As both viewsindicate internal structure, Fig. 5 will be described more in detail.The seat body 10 is composed of molded material. Reference characters 24and 25 indicate sectional areas of internal parts, inserts, or memberswhich are, in effect, integral, in accordance with the invention, withthe seat body. The main body of the seat 10 surrounding the parts 24 and25 is composed, in this example, of a moldable material such as sawdustor wood flour and phenolic resin. Other resins may be used.Thermoplastic resins are also available. Fifteen percent of powderedresin by weight is suitable.

In Fig. 6 is shown a paper bag 28 similar to the usual tea bag. The typeof paper used in the bag is known as 8 lb. to 12 lb. tea bag heat sealedpaper. It is extremely porous which is an advantage. This bag is filledwith a mixture similar to that described above for the body of the seat10. There is, however, a high concentrate of resin. The resin powder maybe 25 to 40 percent. The bag is heat sealed to retain the highconcentrate mix. The bag and its contents provide the parts 24 and 25.

The cover 12 in Fig. 4 has an internal appearance similar to that of theseat 10. Areas 31 and 32 of the cover 12 represent molded in memberswhich are enclosed, initially, by bags 36. These bags are, or may be,identical with the bags 28.

Fig. 7 indicates generally the manner of molding an article inaccordance with the invention and will be referred to solely for thepurpose of describing process steps to be followed. It will beunderstood that any molding and/or heating apparatus may be used andthat the invention is not restricted by apparatus limitations.

The mold is shown as being composed of two parts 41 and 42 havingsuitable mold cavities therein. These parts are separable so as to beloaded with moldable material. Any heating means (not shown) may beprovided. To produce either the seat 10 or the cover 12 a mixture ofwood flour is made with a relatively large amount of resin. This highresin concentrate mixture is placed in the paper bag 28 (or the bag 36).The bag is then sealed by heat. The mold is loaded in accordance withany known mold loading technique with the normal mix orcomposition forthe body of the part to be molded. As the mold is being loaded with theregular mix, one or more of the sealed and filled bags 28 or 36 areplaced in the exact place where reinforcement is needed. Before the moldis closed the bag or bags are covered with a thin layer of the regularmix and thus in effect bury the bag in the material to be molded. Themold is closed and heat and pressure are applied for the needed amountof time to complete the curing cycle. The curing cycle for the articleis substantially unchanged by inclusion of the bag. The high concentrateresin mix in the bag cures along with the material surrounding it andinasmuch as the bag is not only porous but is made of a materialcompatible with the regular mix the entire mass becomes homogeneous sothat when the seat, or other article, is removed from the mold a productis obtained which has embedded in it a portion of high concentrationresin which gives added strength and large screw holding power.

What is claimed is:

I. A molded article which is composed of a filler and a plasticcomponent, a compact unitary portion differing in physicalcharacteristics from the remainder of the article and being of a smallervolume with respect thereto, said unitary portion being embedded in saidarticle and comprising a filler and a plastic component, said last namedplastic component being in higher concentration than in the remainder ofsaid article.

2. A molded article having a compact integral portion of greaterstrength than the remainder of the article, said integral portionexisting in the interior of said article and being of a smaller volumewith respect thereto.

3. A molded article which is composed of a wood flour and phenolicresin, a compact unitary portion dilfering in physical characteristicsfrom the remainder of the article and being of a smaller volume withrespect thereto, said unitary portion being embedded in said article andcomprising wood flour and a phenolic resin, said phenolic resin in saidunitary portion being in higher concentration than in the remainder ofsaid article.

4. A molded article which is composed of thermosetting resin, a compactunitary portion differing in physical characteristics from the remainderof the article and being of a smaller volume with respect thereto, saidunitary portion being embedded in said article and comprising wood flourand a thermosetting resin, said thermosetting resin in said unitaryportion being in higher concentration than in the remainder of saidarticle.

5. A molded article which is composed of wood flour and a thermoplasticresin, a compact unitary portion differing in physical characteristicsfrom the remainder of the article and being of a smaller volume Withrespect thereto, said unitary portion being embedded in said article andcomprising wood flour and a thermoplastic resin being in higherconcentration than in the remainder of said article.

References Cited in the file of this patent UNITED STATES PATENTS322,936 Hoyt July 28, 1885 2,607,012 Lo'etscher Jan. 5, 1937 2,069,756Glancy et al. Feb. 9, 1937 FOREIGN PATENTS 15,625 Great Britain June 30,1914

